OEM 2005 Dodge Sprinter 3500 Timing Cover

2005 Dodge Sprinter 3500 Timing Cover Parts and Q&A

• Q: How to Safely Remove and Install a Timing Cover on 2005 Dodge Sprinter 3500?

  A: Remove the negative battery cable and ensure the engine is where it starts at TDC on cylinder 1. First, drain the coolant and engine oil and next remove the oil filter so oil can enter the pan. Next, with air conditioning still sealed, remove the radiator assembly, engine cover, front cover at the cylinder head, accessory drive belt, high pressure fuel pump, water pump, accessory drive belt pulley, vibration damper and power steering pump. Disconnect the AC compressor's electric cable, detach it from the mounting bolts and put it in the lower part of the engine compartment. With the wires connected, take the generator out and put in an engine support fixture before you take out the oil pan. Take out the coolant hose from the oil-water heat exchanger at the crankcase, then remove all the bolts on the cylinder head to timing cover, then all the timing cover bolts and cover and any other extra parts attached to the timing case cover. Check both hoses and clamps for possible damage and replace them as required. After that, remove the timing chain tensioner and the timing case cover. When installing, check the cylinder head gasket and oil pan gasket, replace any that are damaged and put in a new front crankshaft seal. Put all the extra components you need on the timing case cover, spread sealant on the marked spots with a 1.5 to 2.5 mm thickness and really put the timing case cover within 10 minutes, tighten bolts to 20 Nm. Fit the M8 bolts for the cylinder head on the timing case cover, then tighten to 20 Nm. After that, put on the new timing chain tensioner and its seal. Insert the oil pan at its proper position and use a torque wrench to tighten the M6 bolts to 9 Nm and M8 bolts to 20 Nm. Slide on the belt/pulley vibration damper, secure it with the M8.8 bolt tightened to 200 Nm in two easy steps, plus 90° angle and then repeat with the M10.9 bolt, tightened to 325 Nm and another 90° angle. Once you have set the engine support aside, put in the generator, air conditioning compressor, power steering pump and water pump. Join the coolant hose to the oil-water heat exchanger, put the high pressure fuel pump in place, seal the front cover just below the cylinder block and then fasten all bolts to 20 Nm. Removing the starter retaining lock, tightening the plug for the crankshaft/starter ring gear to 30 Nm and putting on a fresh oil filter and tightening the screw cap are the remaining things to do. Attach the accessory drive belt, radiator assembly and air intake hose and put the proper fluids into the coolant and crankcase before screwing on the oil dipstick. In addition, attach the negative battery cable and start the engine so you can look for leaks while checking for any warnings in the fuel system.